Why Preventive Maintenance Is Crucial for Asset Longevity and Efficiency

You’re not here because everything’s working perfectly. You’ve probably dealt with machines breaking down at the worst possible time—lost productivity, unexpected bills, and frustrated teams scrambling to catch up. Every emergency repair is a reminder of how quickly things can spiral out of control.In this guide, we’ll answer the burning question: Why is preventive maintenance (PM) important, and how can it make your daily work easier? You’ll get plain-language examples, practical checklists, and a step-by-step plan you can apply today. But first, let’s start with the basics. .

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What Is Preventive Maintenance?

Preventive maintenance (PM) is the planned, routine care of assets to keep them safe, reliable, and cost-effective. Instead of waiting for equipment to fail, teams perform scheduled tasks at set time or usage intervals to prevent breakdowns. 

This matters because PM reduces safety incidents, improves uptime and product quality, and avoids the high costs of emergency repairs and rush parts.

Core PM tasks include:

• Cleaning (remove dust, debris, contaminants)
  
• Lubrication (grease/oil bearings, chains, gears)
  
• Tightening (fasteners, belts, electrical connections)
  
• Inspection (visual and functional checks for wear, leaks, vibration)
  
• Calibration (restore sensors/instruments to spec)
  
• Replacing parts (filters, belts, seals, consumables before failure)

When these tasks are scheduled, standardized, and tracked, you get predictable performance, fewer stoppages, and better compliance. The easiest way to manage this at scale is with a CMMS that automates work orders, calendars, parts reservations, and histories

See our preventive maintenance system for how to schedule and track tasks across your sites.

11 Reasons Why Preventive Maintenance Is Important

Below are the clearest answers to “why is preventive maintenance important”, split into business and technical wins your team will feel immediately.

Business benefits

1. Less unplanned downtime
   Planned tasks stop small issues from becoming line-stopping failures, protecting throughput and customer commitments.
   
2. Lower emergency repair costs
   Fewer call-outs, rush shipping fees, and scrap; you replace parts on your terms instead of paying “breakdown pricing.”
   
3. Predictable scheduling & labor planning
   Workloads level out with calendars and routes, improving technician utilization and reducing overtime spikes.
   
4. Audit trails & insurance defensibility
   Documented PMs, checklists, and histories demonstrate due diligence for audits, insurers, and OEM warranty claims.
   
5. Team morale & retention
   Fewer fire-drills and clearer routines reduce stress and burnout—techs spend more time fixing causes, not symptoms.

Technical benefits

1. Higher reliability & availability
   Regular inspections, lubrication, and calibrations increase MTBF and asset uptime across critical equipment.
   
2. Longer asset life
   Clean, aligned, and properly torqued components wear slower, extending lifecycle and deferring capex.
   
3. Safety & compliance readiness
   Scheduled inspections catch hazards early (guards, electrics, pressure systems), reducing incidents and citations.
   
4. Consistent product/service quality
   Controlled conditions (e.g., tension, temperature, vibration) minimize variation, rework, and customer complaints.Energy efficiency
   Clean filters, aligned drives, and well-lubricated bearings cut friction and load, lowering kWh consumption.
   
5. Better spare-parts control
   PMs forecast parts demand; min/max levels and reservations prevent stockouts while avoiding excess inventory.

Tip: Track KPIs like MTBF, MTTR, planned maintenance percentage, and schedule compliance to quantify these gains and fine-tune intervals over time.

Types of Preventive Maintenance

Preventive maintenance isn’t one-size-fits-all. Depending on the asset, teams may apply different scheduling strategies to keep systems performing at their best. Here’s a breakdown of the most common types:

Time-based maintenance (TBM)

This approach schedules maintenance tasks at set time intervals, such as every 10 days or monthly. Time-based maintenance is particularly suitable for equipment that experiences wear and tear at a predictable rate over time. By adhering to a predefined schedule, organizations ensure that crucial maintenance tasks like inspections, lubrication, and replacements are performed consistently. This strategy helps prevent deterioration due to aging components and enables timely identification of issues that might otherwise lead to unexpected failures.

When to use: OEM-required replacements, seals/gaskets, safety inspections where “time in service” drives risk.

Usage-based maintenance (UBM)

Maintenance actions are triggered based on asset usage benchmarks, such as a specific number of kilometers or hours of operation. UBM is advantageous for assets where wear and tear correlate with their usage. Monitoring usage-based metrics helps organizations identify the optimal intervals for maintenance tasks, aligning them with actual asset performance. This approach allows maintenance teams to address issues in equipment that experience higher wear during operation, ensuring components are replaced or serviced when required, rather than solely on a time-based schedule.

When to use: Mobile equipment, compressors, pumps, or assets with variable utilization.

Condition-based maintenance (CBM)

CBM relies on monitoring asset conditions to determine necessary maintenance. Tasks are performed when specific indicators signal declining performance or impending failure. Unlike time or usage-based approaches, CBM offers a more precise way to allocate maintenance efforts. By monitoring variables like temperature, vibration, and pressure, organizations can detect anomalies that might indicate emerging issues. This approach minimizes unnecessary maintenance, as tasks are carried out only when actual deterioration or malfunction is observed, reducing costs and downtime while maximizing asset uptime.

When to use: Assets with accessible sensors or measurable wear signals (e.g., filters with ΔP gauges, rotating equipment).

Predictive maintenance (PdM)

Utilizing condition-monitoring tools, maintenance is executed when predefined thresholds are exceeded, often by tracking performance and parameters. Predictive maintenance builds upon condition-based maintenance by employing advanced data analysis and machine learning. By continuously collecting and analyzing data, organizations can predict asset failures before they occur. This allows maintenance teams to perform targeted interventions precisely when needed, optimizing asset performance, minimizing downtime, and avoiding unnecessary maintenance activities.

When to use: High-criticality assets where avoiding unplanned downtime yields outsized financial or safety value.

Risk-Based Maintenance (RBM)

Risk-based maintenance combines elements of condition-based and predictive maintenance. It assesses an asset’s criticality and the potential consequences of its failure. Assets with higher risk factors receive more frequent monitoring and maintenance, while lower-risk assets undergo less frequent inspections. RBM ensures that resources are allocated efficiently to protect the most crucial aspects of a facility’s operations.

When to use: Mixed fleets—focus resources where failure impact on safety, environment, or production is highest.

Calendar-Based Maintenance

Calendar-based maintenance is similar to time-based maintenance but is specific to a calendar year. The equipment receives maintenance during predefined periods or seasons, ensuring that it remains operational during peak demand times. This approach is common in industries where seasonal variations affect production or service requirements.

When to use: HVAC changeover, storm prep, shutdown turnarounds, or peak/low production windows.

Quick Comparison Table

When to use: HVAC changeover, storm prep, shutdown turnarounds, or peak/low production windows.

Tip: Most programs blend usage-based and condition-based tasks, then layer in risk-based prioritization to aim effort where it matters most—one of the core reasons why preventive maintenance is important for both reliability and cost control.

When Is the Best Time to Implement Preventive Maintenance

Not every asset requires the same level of care. Before building a preventive maintenance plan, it’s important to evaluate which equipment actually benefits from scheduled service.

Here’s how maintenance teams decide when to apply preventive maintenance:

Assets Well-Suited for Preventive Maintenance

• Equipment with predictable wear patterns.
  Parts like belts, filters, and seals that gradually degrade over time are ideal for routine checks.
• Systems that get riskier the longer they run.
  Older machines or heavily used components often show warning signs as they near failure. Intervening early avoids major disruptions.
• Critical machinery tied to core business operations.
  If a breakdown directly halts production, delays shipments, or threatens safety, regular inspections are essential.

Assets Less Suited for Preventive Maintenance

• Components prone to random, non-preventable failures.
  Circuit boards or microchips often fail without warning, making scheduled service less effective.
• Low-priority equipment with no serious impact if it fails.
  For example, decorative lighting or non-essential office fixtures may not justify scheduled maintenance.
• Very costly repairs where run-to-failure is cheaper overall.
  In some cases, replacing older, non-critical assets after failure may be more cost-effective than ongoing servicing.

A good rule of thumb: start small. Prioritize the most critical assets first, then expand your preventive maintenance program across the rest of the facility over time.

Then, Set the Right Frequency (Time vs Usage)

Once you’ve shortlisted assets, decide how often to maintain them based on risk and how wear accumulates:

• Time-based scheduling: Fixed intervals (daily/weekly/monthly/annual). Best for age-related risks, contamination build-up, or regulatory checks.
  
• Usage-based scheduling: Triggered by meters (run hours, cycles, miles). Best when wear correlates with runtime or throughput.

Starter frequency guidance

• Daily: Operator walkarounds and housekeeping.
  
• Weekly: Quick lubrication and safety checks on high-use equipment.
  
• Monthly: Deeper inspections and tension/alignment checks.
  
• Quarterly: System-level alignments, leak detection, performance tests.
  
• Annual: Full calibrations and planned replacements during outage windows.

Sample PM Checklist (by System/Area)

Examples of Preventive Maintenance Across Industries

Preventive maintenance applies across nearly every industry that relies on physical assets. Here’s how different sectors put it into action:

Step-by-Step: Implement an Effective Preventive Maintenance Program

Use this practical six-step playbook to build a preventive maintenance program that cuts downtime, improves safety, and proves why preventive maintenance is important with measurable KPIs.

Inventory & criticality (RCM light)

• Build your asset register: Capture make/model, serials, location, OEM manuals, meters, and spare parts.
  
• Rank criticality: Score each asset by probability of failure × consequence (safety, downtime, quality, environment, cost).
  
• Decide PM candidates: Prioritize high-critical assets and any equipment showing age- or usage-related wear.

Create PM library & SOPs (task instructions, torque specs, photos)

• Standardize tasks: Define cleaning, lubrication, tightening, inspection, calibration, and planned replacements.
  
• Write clear SOPs: Steps, safety/LOTO, tools, torque specs, pass/fail criteria, and expected duration.
  
• Add visual aids: Photos/diagrams of points to lube, tension checks, gauges, and acceptable tolerances.

Build schedules (time/usage/condition) aligned to OEM guidance

• Start with OEM intervals; convert to time-based or usage-based triggers (hours, cycles, miles).
  
• Layer condition checks: Vibration, temperature, pressure drop (ΔP), or trend thresholds where practical.
  
• Route & group work: Bundle tasks by area/asset to cut travel time and align with outages/seasonal windows.

Assign roles & train technicians

• Define ownership: RACI for planning, execution, parts, and approval.
  
• Close skill gaps: Short toolbox talks, shadowing, and certification on critical procedures.
  
• Create feedback loops: Techs flag recurring defects and SOP improvements directly on work orders.

Digitize with a CMMS (work orders, histories, reminders, mobile/offline)

• Automate the admin: Auto-generate work orders from calendars/meters; attach SOPs, photos, and checklists.
  
• Strengthen traceability: Capture completion notes, meter readings, and parts usage for every job.
  
• Mobilize the floor: Technicians receive tasks on mobile (offline capable), scan barcodes/QRs, and upload evidence.
  
• Plan parts proactively: Reserve critical spares against upcoming PMs; maintain min/max levels tied to schedules.
  See how this works in practice with our preventive maintenance system.

Monitor & optimize (review failures, right-size intervals)

• Track KPIs: MTBF, MTTR, Planned Maintenance %, schedule compliance, backlog age, and wrench time.
  
• Right-size frequencies: Shorten intervals on emerging issues; safely extend where data shows low risk.
  
• Eliminate repeat failures: Do quick RCAs; update SOPs, add condition checks, and adjust spare strategies.
  
• Quarterly review: Re-rank criticality, prune low-value tasks, and re-balance labor across routes.

Outcome: A living PM program that targets real failure modes, reduces downtime and cost, and proves why preventive maintenance is important with measurable results.

Spare Parts, Inventory & Uptime Insurance

Treat your storeroom as uptime insurance: the right part, in the right bin, at the right time.

• Keep critical spares on site. Identify A-critical components (single points of failure, long lead times, safety impact) and hold local stock; document acceptable substitutes and cross-refs.
  
• Set min/max levels by risk and demand. Use consumption history + supplier lead time to calculate safety stock, then set min/max; review quarterly or after major failures/usage shifts.
  
• Barcode everything for fast picks. Label bins and parts; enable scan-to-issue and scan-to-receive so techs spend minutes—not hours—finding what they need.
  
• Tie parts to PM tasks. Link BOMs and kits to each PM; the CMMS should auto-reserve parts when a work order is scheduled and release them if it’s deferred.
  
• Pre-kit recurring jobs. Build grab-and-go PM kits (gaskets, filters, fasteners) per asset family to compress wrench time and reduce missed items.
  
• Standardize & rationalize SKUs. Consolidate equivalent parts, eliminate duplicates, and prefer multi-asset components to lower carrying costs.
  
• Use vendor SLAs wisely. For non-critical spares, lean on supplier agreements (delivery SLAs, consignment, VMI) to keep cash light without risking downtime.
  
• Cycle count > annual counts. Weekly micro-audits of high-value bins keep accuracy high and prevent surprise stockouts.
  
• Track parts KPIs. Monitor stockouts, turns, obsolete value, reservation accuracy, and pick time; adjust min/max and PM kits from real data.
  
• Plan for obsolescence. Flag end-of-life parts, buy last-time quantities if justified, and list refurb vendors to bridge gaps.

Bottom line: pairing critical spares + barcoding + PM-linked reservations turns your storeroom into a competitive advantage—and is a concrete reason why preventive maintenance is important for uptime and cost control.

Challenges Of Preventive Maintenance

Despite its merits, preventive maintenance carries potential drawbacks. Challenges encompass:

Upfront Costs: Initial investments in resources, equipment, training, and system setup can pose financial challenges, particularly for small businesses.

Mitigate: Phase the rollout—start with top-critical assets, reuse task templates/SOPs, and bundle routes to shorten setup. Use calendars and meters to automate recurrence instead of manual planning.

Possible Over–Maintenance: Inadequate planning might lead to unnecessary frequent servicing, causing resource wastage.

Mitigate: Review MTBF, schedule compliance, and failure history quarterly; switch low-value time-based jobs to usage/condition triggers; enable skip logic when thresholds are healthy.

Resource Commitment: Regular maintenance demands dedicated personnel, potentially straining available manpower.

Mitigate: Auto-assign by skills and location, balance capacity with calendars, and group work into routes. Mobile checklists and photo evidence reduce rework.

Equipment Downtime: Scheduled maintenance, though designed to prevent unplanned downtime, can induce operational pauses that require management.

Mitigate: Bundle tasks into outage windows, set blackout periods during production peaks, pre-kit parts, and use approvals so only high-value PMs run during busy shifts.

Complex Scheduling: With expanding asset numbers, scheduling preventive maintenance for each piece of equipment becomes intricate.

Mitigate: Mix time + usage triggers, stagger recurrences, and use route grouping by area/line. Dashboards surface conflicts before they hit the floor.

Intentional run-to-failure (R2F) cases: Assumptions change (lead times, safety), turning cheap failures into costly ones.

Mitigate: Document R2F policy per asset, add inspection-only WOs, keep critical spares noted, and set alerts to revisit the decision when costs/downtime exceed thresholds.

Parts & lead-time shocks: PMs slip because the part isn’t available.

Mitigate: Tie BOMs and auto-reservations to PM schedules, maintain min/max levels, and surface earliest-available dates. (See the Spare Parts, Inventory & Uptime Insurance section for the full workflow.)

Data quality & adoption: Bad meters and incomplete checklists drive bad decisions.

Mitigate: Require meter reads and mandatory fields on closeout; use standardized SOPs and photo uploads; run brief toolbox talks to keep data consistent.

Rule of thumb: If a task doesn’t reduce failure risk, improve safety/compliance, or lower total cost, defer or delete it. Your CMMS’s grouping, auto-assign, routes, skills, and calendars keep effort focused while avoiding over-maintenance.

Leveraging Technology: CMMS and Maintenance Tools

As we mentioned earlier, running a preventive maintenance program manually can get messy fast. As the number of assets grows, tracking service dates, managing technician workloads, and maintaining detailed records become harder without the right tools.

That’s where a Computerized Maintenance Management System (CMMS) comes in.

A CMMS is designed to organize, automate, and optimize maintenance operations. It acts as a digital hub where teams can schedule tasks, track work orders, monitor asset histories, and generate performance reports — all from one place.

Here’s how a CMMS supports preventive maintenance:

• Centralized Asset Records: Store detailed information about each piece of equipment, including service logs, manuals, and warranty data.
• Automated Scheduling: Set recurring maintenance tasks so inspections, calibrations, and replacements are never missed.
• Mobile Access: Technicians can view assignments, update work orders, and log service activities directly from the field.
• Performance Analytics: Generate reports on completed tasks, downtime trends, and asset reliability to fine-tune your maintenance strategy.
• Regulatory Compliance: Keep all maintenance records organized and ready for audits or inspections.

eWorkOrders

When it comes to choosing a CMMS platform, eWorkOrders stands out as a notable option. Our solution combines ease of use with powerful features tailored to streamline preventive maintenance. Thousands of businesses—including industry leaders like McDonald’s, KFC, and Honda—trust our software to reduce downtime, extend asset life, and keep maintenance teams running smoothly. Learn how other companies successfully implement PM strategies in these client testimonials.

But don’t just take our word for it. Here’s how Kings River Packing improved with eWorkOrders:

• Problem:
  The company was managing maintenance using spreadsheets and paper across multiple sites. Keeping up with service schedules, spare parts, and technician workloads was confusing and inefficient, especially as the business grew.
• Solution:
  They switched to eWorkOrders CMMS, which centralized all maintenance tasks, automated scheduling, and gave technicians mobile access to update work orders on the go. The system also handled inventory management, so they no longer needed separate tools for purchase orders.
• Results:
  75% increase in productivity
  • 80% reduction in downtime
  • $500,000+ saved annually
  • Simplified compliance and reporting

Seasonal & Environmental Considerations 

Seasonal conditions change failure risk. Group these summer and winter tasks into sections so teams can expand only what they need and schedule work in advance.

▸ Summer: Heat, Humidity, Dust/Pollen, Electrical Load

• Cooling capacity & coils: Wash condenser/evaporator coils; verify ΔT before/after; check fan belts, alignment, and motor amps.
  
• Filters & airflow: Increase inspection/change frequency; clear intakes on compressors/air handlers; clean sensor heads and enclosures.
  
• Electrical hot-spots: Infrared-scan panels, MCCs, and breakers; tighten lugs/terminals; confirm ventilation for drives/UPS rooms.
  
• Humidity & condensation: Inspect drain pans/traps, dehumidifiers, and cabinet gaskets; treat cooling towers and verify water quality.
  
• Dust/pollen control: Add pre-filters where feasible; blow out cabinets (ESD-safe); protect exposed bearings and slides with correct lubrication.
  
• Load management: Stagger start sequences; test UPS transfer; exercise generators under load; confirm alarms and setpoints.

▸ Winter: Freeze Risk & Fuel Systems

• Freeze protection: Test heat-trace circuits; insulate/examine exposed piping; verify glycol concentration; drain/bleed idle outdoor lines.
  
• Fuel systems & gensets: Winterize diesel (additives, water separation); maintain tank levels to limit condensation; test block heaters and cold starts.
  
• Lubricants & hydraulics: Switch to winter-grade oils/greases where specified; warm-up procedures for hydraulics; check hoses/seals for brittleness.
  
• Doors, docks & envelopes: Inspect dock levelers, door seals, and air curtains; prevent cold ingress that stresses HVAC and sensors.
  
• Batteries & IAQ: Check forklift/backup battery health (capacity drops in cold); verify CO sensors and flue integrity on combustion equipment.

Implementation tip: In your CMMS, tag these as seasonal PM sets and schedule via calendars—activate the relevant accordion block on-page, and activate the matching PM routes in the system ahead of each season.

Conclusion

The question isn’t whether assets will fail—it’s when. That’s exactly why preventive maintenance is important.

By staying ahead of issues with regular inspections, scheduled service, and proactive care, companies protect both their equipment and their bottom line. Unplanned downtime decreases, costly emergency repairs become less frequent, and teams can concentrate on maintaining smooth operations.

FAQs

What is preventive maintenance, and its importance?

It’s essentially performing regular checkups on your equipment before issues arise. The point is to catch small problems early, so you don’t end up with huge repairs or downtime later. It’s important because it saves money, keeps things running smoothly, and prevents emergencies.

What is the goal of preventive maintenance?

Simple: avoid breakdowns. You stay ahead of wear and tear, fix small things early, and keep everything working without sudden surprises or expensive repairs.

What is the major benefit of preventive maintenance?

You save a ton of money in the long run. Emergency repairs and downtime cost way more than just doing regular upkeep. Plus, your equipment lasts longer and stays safer.

What is the purpose of planned preventive maintenance?

It helps you stay organized. Instead of fixing stuff last minute, you plan services ahead based on time or usage. That way, nothing gets missed, and everything stays on track without panic.